EP2121219A1

EP2121219A1 - Method for processing, in particular casting, a material, casting mould for carrying out the method and articles produced by the method or in the casting mould

Info

Publication number: EP2121219A1
Application number: EP07846382A
Authority: EP
Inventors: Marc Menge; Holger Oppelt; Uwe Lange
Original assignee: KSM Castings GmbH
Current assignee: KSM Castings Group GmbH
Priority date: 2006-12-09
Filing date: 2007-12-04
Publication date: 2009-11-25
Anticipated expiration: 2027-12-04
Also published as: PL2121219T3; DE102006058145A1; US20100166596A1; WO2008071152A1; EP2121219B9; CN101594950A; US8763677B2; EP2121219B2; EP2842660A1; ES2552009T3; EP2121219B1; CN101594950B; HUE026352T2; US20140308160A1

Abstract

The invention relates to a method for producing articles in moulds, the moulds themselves and articles produced by the method and/or in the moulds.

Description

Method for processing, in particular casting, a material, casting mold for carrying out the method and articles produced by the method or in the casting mold

The invention relates to a method of processing a material, which is first of its solid state in a flowable state and then poured into a mold in which the material is then solidified. Furthermore, the invention relates to molds for carrying out the method and to articles which have been produced or produced by the processes and / or in such molds.

As a casting method, in particular as gravity casting, four casting methods have proven successful, namely the bottom casting, the side casting, the head casting and the tilting casting, which have mutually certain advantages, but all together have certain disadvantages.

Thus, for example, the bottom casting results in the most laminar mold filling, however, during the solidification process, the coldest material is in the mentioned feeder or riser, ie the storage space from which material is to be fed during solidification, so that here the make-up is ensured by larger feeder dimensions must become.

While the side casting is relatively hot material in the feeder, however, results in a more turbulent mold filling than the bottom casting.

While head casting is the hottest material in the riser or feeder, so that although a good make-up with the lowest feed volume, but the quality of the castings depending on the filling level deteriorated by turbulence.

In the case of tilted casting, which also contains the hottest material in the feeder, unintended turbulences and flow lines are created on the casting surface. The flow direction of the liquid material is determined by the contour of the casting and thus leads to overheating areas in the mold and thus also in the casting.

The object of the present invention was to avoid the disadvantages of the previously known casting methods and to provide methods for processing materials which, with optimal laminar vortex-free mold filling and optimal Nachspeisung by the hottest metal from a storage room and thus smaller storage or feeder volume enable. In addition, overheating of contour-related accumulations of material should be avoided and cycle, material, energy, transport and cutting performance should be saved. Furthermore, the production of large-scale and complicated castings should be simplified and thus cheapened. Another task aspect was the creation of appropriate casting molds for the rational and high quality production of castings.

According to the invention, the process for processing materials by introducing them into a flowable state and introducing them into a mold is first characterized in that the introduction into the mold takes place according to the principle of the bottom casting and the solidification according to the principle of the head casting. In other words, it is first brought the material by heating in a flowable state and introduced into a mold or in the mold cavity or cavity according to the principle of the bottom casting and the solidification is carried out according to the principle of Kopfgusses / Kippgusses.

The introduction of the material into the cavity of the mold from below by a casting run on the type of bottom casting by the melt first from above into an at least partially higher than the cavity lying Eingußümpel, from there through a downwardly leading inlet, then about a curvature - the inlet - upwards into a storage space located below the cavity and is introduced through the outlet into the cavity and the solidification then takes place with the pantry upwards in the manner of Kopfgusses by before the solidification of the material, the mold is pivoted , so that then the pantry the Speiserbzw. Steigerfunktion takes over. In order to prevent the melt from flowing out of the pouring basin during pivoting and after that, it can be advantageous if a slide lying in the casting run in front of the cavity - in the flow direction of the melt - is activated in good time before or during the pivoting of the mold.

Instead of a slide, however, a closure can also be provided on the pouring pond, which is activated before pivoting.

It is expedient here if the pivoting of the mold takes place about an axis which runs at least approximately parallel to the parting plane or to the parting plane of the mold.

It can also be advantageous if the cavity and the run and thus also the parting line (s) or parting line (s) - level (s) are provided or arranged at an angle to each other. It may be either the casting run or the cavity run obliquely, but it can also be both cavity and run at an oblique angle to the horizontal, wherein the cavity and run to each other can include an obtuse angle. However, it is also possible for the cavity and / or the casting run to occupy a shallow angle to the horizontal.

It may be particularly advantageous if cavity and run are provided at such an angle to each other and are pivoted together at such an angle and in such a direction that upon reaching a position of the storage space in which this the function of the riser or feeder can take over, the casting run has not reached the horizontal, it is particularly advantageous if the pivoting of the mold takes place in one direction, such that the casting run leads, so that in the solidification position of the run at least slightly upwards and a Leakage of the melt from the pantry, which then, as already mentioned, acts as a riser or feeder is not possible.

A development of the invention relates to a mold or mold, which has a reservoir below the cavity into which the pouring leads, wherein the opening into the reservoir region of the casting a section - the inlet - has, which is lower than the reservoir.

The mold may further be characterized in that the cavity and the run are not provided parallel to each other, but at an angle to each other. In this case, the mold or mold may be formed such that both, ie cavity and run, are inclined, wherein they can form an obtuse angle to each other. The angle can be chosen such that upon pivoting of the mold into the position in which the storage space comes to lie over the cavity - the solidification position - and the storage space can act as a feeder or riser, the casting run in a the leakage of Melt from the storage space avoiding position by this at least slightly protrudes with respect to the horizontal, at least slightly upwards. Such a design of the casting mold is advantageous in that the cavity and the casting run are arranged relative to one another and the mold is pivoted in such a way that the casting run leads.

The pivotable mold, in which the mold halves surrounding both the casting run and the reservoir and the cavity are separated by corresponding parting lines, is expediently designed such that the pivoting takes place about an axis which extends at least approximately parallel to the plane of the parting plane ,

This mold is - with the reservoir down - filled according to the bottom casting principle with melt, the reservoir is located below the cavity and in the pivoted mold, the solidification of the melt - with the then acting as feeder or riser pantry upwards.

In order to prevent the leakage of melt during or after the pivoting, it may also be advantageous if the casting mold has a closure on the pouring basin or a slide is provided in the region of the casting run, wherein the closure or slide is actuated before or in time during pivoting. The invention also relates to castings which are produced by the inventive method and / or by means of the casting molds according to the invention, these castings in a particularly expedient and advantageous manner by gravity produced light metal, in particular aluminum alloys - exist.

The invention will be explained in more detail with reference to FIGS. 1 to 9.

In this case, Figures 1 to 4 show conventional casting methods according to the prior art and Figures 5 and 9, the casting method according to the invention.

It shows the

FIG. 1 schematically shows the casting process after the so-called bottom casting,

FIG. 2 shows the casting process after the side casting,

Figure 3 shows the casting process after the head casting and

FIG. 4 shows the casting method after the tilting casting.

In the figures 1 to 4, the indicated mold or mold is respectively denoted by 1A, 1 B, 1C and 1 D and the mold cavity or the cavity with 1a - 1d.

In each of FIGS. 1 to 4, a feeder or riser 2a to 2d is provided, from which the so-called make-up can take place when the casting solidifies.

In the case of bottom casting, side casting and head casting according to FIGS. 1 to 3, the casting molds are upright and in FIGS. 1 and 2 the melt is introduced via the pouring basins 4a, 4b. In the head casting according to FIG. 3 and in the tilted casting according to FIG. 4, the riser 2c, 2d also serves pouring basins. When dumping according to Figure 4 takes place - in the example shown here - the filling of the melt first in the horizontal state of the mold 1 D in the container 2d ^' and the mold 1 D is pivoted according to the arrow 3, the melt passes through the feeder 2d, to the mold is upright and in this position, the solidification of the material takes place with the feeder 2d upwards. In the case of bottom casting and side casting in accordance with FIGS. 1 and 2, the material supply takes place above the gray run 5 a, 5 b initially into the pouring basin and from there into the cavity 1 a, 1 b. In the bottom casting according to FIG. 1, the inlet 6 adjoins the inlet pool 4 a, which merges into an inlet region 7, which lies deeper here than the cavity 1 a, and through the outlet 8 the melt enters the cavity 1 e.

It can be seen that in the bottom casting according to FIG. 1 the most laminar mold filling is produced.

In the case of the side casting according to FIG. 2, the mold filling takes place via the elevation of the

Bath mirror in the outlet at the mold cavity and is therefore less laminar than the

Ground cast.

In the head casting according to FIG. 3, the most turbulent mold charge is present, which leads to greater enrichment of the melt with oxides, gas bubbles and foam.

The flow direction of the material is also determined by the contour of the casting and thus leads to overheating areas in the mold, from which errors in the casting arise.

When casting in Kippgießverfahren according to Figure 4 and when casting by the Kopfgussverfahren according to Figure 3, one has the hottest material in the feeder, so the best make-up, but results, as already mentioned, instead of the desired laminar mold filling a turbulent.

The bottom casting according to FIG. 1, as already mentioned, produces the most laminar mold filling, while the side casting according to FIG. 2 has an embodiment which has already been impaired with respect to laminar mold filling and both casting methods, ie bottom casting and side casting, have the disadvantage that the coldest material is present in the feeder or Steiger is located and thus when solidification optimal make-up can only be done by larger feeders. In the present invention, which is first explained in more detail with reference to FIGS. 5, 6 and 7, the advantages of bottom and head casting, ie the best laminar mold filling, are combined with the advantage that during solidification the hottest metal is in the feeder.

In this case, according to Figure 5, the pouring into the indicated with 1 E mold practically as in Figure 1, ie after the Bodengussverfahren by the melt passes through the also gray deposited run 5c into the cavity 1e. The melt introduced into the pouring pond 4e flows downwards through the inlet 6a, through the region extending below a storage space 9, through the inlet 7a through the storage space 9 and from there through the outlet 8a of the storage space 9 into the cavity 1e. Before solidification of the material, for example, as a function of a certain temperature, the entire mold 1 E is pivoted, and as shown in Figure 6, here by about 180 °, about the axis I according to the direction of rotation II the storage space 9 upwards, so that this storage space 9 is now effective as a feeder or riser until the material is solidified.

In Figure 7, a position of the mold or mold 1 E is shown after it has been pivoted from the position of Figure 5 by about 90 °. In this case, the parting line 10 between the two mold halves 1 E ^' and 1 E ^{"can be seen} and the pivot axis I ₁ extends parallel and through the plane formed by the parting lines 10. In Figure 7, the end face of the cavity facing the viewer can also be seen 1e and the end face of the storage space 9 and the inlet 7a and the pouring basin 4e.

In many cases, it will be irrelevant whether, in the position of FIG. 6, melt leaves the casting pool 4e, the inlet 6a or the inlet 7a after the melt present there is no longer needed for the following phases of the casting process.

It may be expedient if the mold 1 E between the position it occupies shortly before it is in the position shown in Figure 7 and in a position shortly thereafter, quickly moved, so that melt from the cavity and the reservoir practically can not leak. In the area of the pouring pond 4e, however, a closure 11 can also be provided or in the region of the inlet a slide 12, which are actuated in good time before or during pivoting, so that the casting run is completed there.

However, the pivoting can also be pivoted about a horizontal or horizontal or at least approximately parallel to the plane of the parting line 10 extending axis, for example, at least approximately to the axis extending perpendicular thereto III. It may be advantageous if the pivoting takes place in the direction of the arrow III ^' , so that the casting run or the pouring pond precedes and melt until it reaches a position with the reservoir 9 upwards at least this can not leak. The pivoting can also take place about other axes or curves than the illustrated, for example, composed of the axes shown axes or curves; when using a shutter or slide, the direction of rotation is less critical with respect to the leakage of melt from the runner.

In FIGS. 8 and 9, cavity 20 and at least parts of the casting run 21, namely the inlet 22, are arranged at an angle to one another, namely at an obtuse angle.

It is again recognizable the Eingusstümpel 23 and the curved inlet 24, which opens into the reservoir 25 and this goes through an outlet 26 into the cavity. Cavity 20, the reservoir 25 and inlet 24 may be arranged to each other so that the inlet 24 is lower than the reservoir 25 and this in turn is lower than the cavity 20. In some cases, it may also be advantageous or sufficient if the inlet 24 is not placed below the storage space 25. In the figures 8 and 9 are cavity and inlet, as already mentioned, provided at an obtuse angle 26 to each other and both include each an angle 27, 28 a to a plane 29 which extends at least approximately perpendicular to the horizontal. After the introduction of the melt and in good time before the solidification of the same, the mold 30 is pivoted into the position shown in Figure 9, about the axis 31, which is at least approximately parallel to the parting line 32 of the mold 30, and expediently in a pivoting direction of the Arrows 33, so that the runner 21 leading to the Eingusteümpel 23, to a position of Figure 9, wherein the cavity 20 is brought into a position such that the storage space 25 is now above the cavity 20 and the storage space 25, the function a riser or feeder can take over.

The pivoting is done so far that the inlet 22, the horizontal 34 has not quite reached, so it can leak no or little melt.

It can be seen that the method according to the invention or the casting molds according to the invention make it possible to cast according to the principle of bottom casting with a laminar mold filling that is optimal in comparison with the other casting methods and solidify according to the principle of head casting, which in turn results in the best possible make-up.

The invention further relates to castings which are produced by the method according to the invention and / or in the casting molds according to the invention. Although the method according to the invention is particularly suitable for the processing of light metal, in particular light metal alloys, such as aluminum alloys, the invention is not limited to the use in light metal alloys, but other materials according to the invention can also be processed, including non-metallic materials.

LIST OF REFERENCE NUMBERS

1A to 1D casting mold

1a to 1e cavity

2a to 2d feeder / riser

2d 'container

3 arrow

4a-4d Gutterpond

5a, 5b, 5c casting

6 enema

7,7a inlet

8,8a outlet

9 storage container

I axis

10 parting line

1E mold (mold)

1 E ^' , 1 E ^" mold halves

11 closure

12 slides

20 cavity

21 watering

22 enema

23 ponds Intake

pantry

angle

WL

shape

axis

parting line

pan direction

Claims

claims

1. A method for processing a material by bringing it into a flowable state and introducing it into a mold, characterized in that the introduction of the material into the mold according to the principle of the bottom casting and the solidification takes place according to the principle of the head casting.

2. A method for casting a material by bringing it into a flowable state by heating and introduction into a mold, characterized in that the introduction of the material into the mold according to the principle of the bottom casting and the solidification takes place according to the principle of the head casting.

3. A method, in particular according to one of claims 1 or 2, characterized in that the introduction of the material into the cavity of the mold from below (in the manner of the bottom casting), wherein the material - as seen in the flow direction - first by a casting , Then flows through a lying in front of the cavity and arranged below the same pantry and from there into the cavity and wherein the solidification with the pantry upwards (on the type of Kopfgusses) takes place.

4. Method, in particular according to one of claims 1 to 3, characterized in that after the introduction of the material, the mold is pivoted, so that the storage space takes over the feeder or Steigerfunktion.

5. Method, in particular according to one of the preceding claims, characterized in that the casting runway has an area which during the introduction of the material is lower than the pantry.

6. Method, in particular according to one of the preceding claims, characterized in that in the runner and cavity, a slider is provided which is activated prior to pivoting.

7. A method, in particular according to one of the preceding claims, characterized in that a closure is provided on the Eingusteümpel the mold, which is activated prior to pivoting.

8. A method, in particular according to one of the preceding claims, characterized in that the pivoting of the mold takes place about an axis which extends at least approximately parallel to their joints - plane or planes.

9. Method, in particular according to one of the preceding claims, characterized in that the cavity and the run are arranged at an angle to each other.

10.Verfahren, in particular according to claim 9, characterized in that both the cavity and the casting run are arranged at an angle to a horizontal plane extending between them.

11.Verfahren, in particular according to claim 9 or 10, characterized in that cavity and casting run each other include an obtuse angle.

12. Method, in particular according to one of claims 9 to 11, characterized in that the cavity and / or casting run form an obtuse angle to a horizontal plane.

13. A method, in particular according to one of claims 9 to 12, characterized in that the cavity and the run are provided at such an angle to each other and are pivoted at such an angle about the pivot axis and in such a direction that upon reaching a position of the storage space in which it can take over the function as a feeder 5 or riser S, the casting run has not yet reached the horizontal.

14. Method, in particular according to one of the preceding claims, characterized in that the pivoting of the mold takes place in such a direction that the casting run leads.

15. A method for casting a flowable material in a mold by the material is introduced into a pouring basin, from there through a subsequent inlet, further through an inlet which is at least partially lower than a storage space, which in turn at least partially is lower than the cavity and from there through an outlet of the storage space into the cavity and wherein the mold is pivoted before the solidification of the material, such that the storage space is effective as a feeder or riser.

16. Mold or mold, in particular for carrying out a method according to at least one of the preceding claims, characterized in that the mold has a reservoir below the inlet into the cavity.

17. casting mold, in particular according to claim 16, characterized in that the opening into the reservoir casting runway has a portion which is lower than the reservoir.

18. casting mold, in particular according to claim 16 or 17, characterized in that the cavity and the run are provided to each other at an angle.

19. Casting mold, in particular according to one of claims 16 to 18, characterized in that both the cavity and the casting run at an angle to a running between them, at least approximately are arranged perpendicular to the horizontal plane extending.

20. Casting mold, in particular according to one of claims 18 or 19, characterized in that the cavity and casting run are provided to each other at an obtuse angle.

21. Casting mold, in particular according to one of claims 16 to 20, characterized in that the cavity and the casting run are provided at such an angle to each other, that upon pivoting of the mold into a position in which the storage space is above the cavity - Solidification position - and the storage space can be effective as a feeder or riser, the casting is located in a leakage of liquid casting material from the storage space avoiding position.

22, casting mold, in particular according to claim 21, characterized in that the run in the solidification position to the horizontal has obliquely upwards.

23. Casting mold, in particular according to one of claims 16 to 22, characterized in that the cavity and casting run are arranged relative to each other and the mold is pivotable such that the casting run leads.

24. casting mold, in particular pivotable mold, in which two mold halves surrounding both the casting run, as well as the storage space and the cavity are separated by parting lines and the mold is pivotable about an axis which extends at least approximately parallel to its parting plane.

25, mold, in particular according to one of claims 16 to 24, characterized in that - with the reservoir down - after the bottom casting principle with melt can be filled and that the mold is pivotable and the solidification of the melt - with the then as feeder or Steiger effective pantry up - done.

26. Casting mold, in particular according to one of claims 16 to 25, characterized in that a closure is provided on the pouring pond.

27. Mold, in particular according to one of claims 16 to 26, characterized in that a slider is provided in the region of the casting run.

28. A cast product, characterized in that it is produced according to at least one of the methods described in claims 1 to 15 and / or in a casting mold according to at least one of claims 16 to 27.

29. Cast product, characterized in that it consists of a light metal produced according to at least one of the preceding claims by gravity, in particular an aluminum alloy.